DI-19

Rear Differential (T-type)

DIFFERENTIALS

4. Rear Differential (T-type)

A: REMOVAL

1) Shift the select lever or gear shift lever to neutral.

2) Disconnect the ground cable from battery.

3) Release the parking brake.

4) Loosen the wheel nuts.

5) Lift up the vehicle.

6) Remove the rear wheels.

7) Disconnect the oil temperature sensor connec-

tor. (H5)

8) Drain differential gear oil. <Ref. to DI-16, RE-

PLACEMENT, Differential Gear Oil.>

9) Remove the rear exhaust pipe.

• Except for STI model

<Ref. to EX(w/o STI)-50, REMOVAL, Rear Exhaust

Pipe.>

• STI model

<Ref. to EX(STI)-12, REMOVAL, Rear Exhaust

Pipe.>

10) Remove the center exhaust cover.

11) Remove the propeller shaft. <Ref. to DS-12,

REMOVAL, Propeller Shaft.>

12) Loosen the self-lock nuts which hold the rear

differential to the rear sub frame assembly.

13) Remove the DOJ of rear drive shaft from rear

differential using ST.

NOTE:

When removing the DOJ from the rear differential,

fit the ST to the bolts as shown in the figure so as

not to damage the side retainer.

ST 28099PA100 DRIVE SHAFT REMOVER

14) Set the rear differential to transmission jack.

(A) Oil temperature sensor connector

DI-00991

(A)

DI-00972

(A) Bolt

DI-00996

DI-00270

(A)

DI-00730

15WRX_STI_US_EN.book 19 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-20

Rear Differential (T-type)

DIFFERENTIALS

15) Remove the rear differential front member.

16) Remove the self-lock nuts which hold the rear

differential to the rear sub frame assembly.

17) Pull out the rear differential stud bolt from rear

differential mount bushing.

NOTE:

When removing the stud bolt from the rear differen-

tial mount bushing, carefully adjust the angle and

location of transmission jack and jack stand, if nec-

essary.

18) Lower the transmission jack.

19) Pull out the rear drive shaft from the rear differ-

ential.

NOTE:

If it is difficult to pull out the rear drive shaft from the

rear differential, remove it using a ST.

ST 28099PA100 DRIVE SHAFT REMOVER

20) Lower the transmission jack.

21) Secure the rear drive shaft to rear lateral link

using wire.

22) Remove the rear differential member plate from

rear differential.

DI-00731

DI-00996

DI-00733

(A) Rear differential member plate

DI-00974

DI-00734

DI-00359

(A)

15WRX_STI_US_EN.book 20 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-21

Rear Differential (T-type)

DIFFERENTIALS

B: INSTALLATION

1) Attach the rear differential member plate to the

rear differential.

2) Set the rear differential to transmission jack.

3) Set the ST to the rear differential.

ST 28099PA090 OIL SEAL PROTECTOR

4) Insert the rear drive shaft until the spline portion

of the rear drive shaft exceeds the side oil seal.

5) Remove ST from rear differential.

6) Push the rear differential from side to side to in-

sert the DOJ into rear differential completely.

7) Adjust the transmission jack, if necessary, and

insert the rear differential stud bolt into the rear dif-

ferential mount bushing properly.

8) After inserting the rear differential stud bolt into

the rear differential mount bushing, lift up the trans-

mission jack and align the rear differential to its at-

tachment position.

(A) Rear differential member plate

DI-00359

(A)

DI-00279

DI-00280

DI-00735

DI-00733

DI-00736

15WRX_STI_US_EN.book 21 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-22

Rear Differential (T-type)

DIFFERENTIALS

9) Tighten a new self-locking nut temporarily to the

rear differential stud bolt.

10) Install the rear differential front member, and

temporarily attach and tighten a new self-locking

nut.

11) Remove the transmission jack.

12) Tighten the self-locking nut.

Tightening torque:

T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

T2: 110 N·m (11.2 kgf-m, 81.1 ft-lb)

13) Tighten the self-locking nut.

Tightening torque:

70 N·m (7.1 kgf-m, 51.6 ft-lb)

14) Install the propeller shaft. <Ref. to DS-14, IN-

STALLATION, Propeller Shaft.>

15) Install the center exhaust cover.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

16) Install the rear exhaust pipe.

• Except for STI model

<Ref. to EX(w/o STI)-51, INSTALLATION, Rear

Exhaust Pipe.>

• STI model

<Ref. to EX(STI)-12, INSTALLATION, Rear Ex-

haust Pipe.>

17) Fill differential gear oil. <Ref. to DI-16, RE-

PLACEMENT, Differential Gear Oil.>

18) Installing procedure hereafter is in the reverse

order of removal.

DI-00996

DI-00981

DI-00737

DI-00996

DI-00972

15WRX_STI_US_EN.book 22 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-23

Rear Differential (T-type)

DIFFERENTIALS

C: DISASSEMBLY

1. T-TYPE (B1, B2)

To detect the real cause of trouble, inspect the fol-

lowing items before disassembling.

• Tooth contact and backlash between hypoid

driven gear and drive pinion

• Hypoid driven gear runout on its back surface

• Total preload of drive pinion

1) Set the ST on vise and install the differential as-

sembly to ST.

ST 398217700 ATTACHMENT SET

2) Remove the drain plug and filler plug.

3) Remove the air breather cap.

NOTE:

• Do not attempt to remove the air breather cap

unless necessary.

• Whenever the air breather cap is removed, re-

place it with a new part.

4) Remove the bolts, and then remove the rear

cover.

5) Remove the side retainer attachment bolts, set

the ST to differential case, and extract the side re-

tainers RH and LH with a puller.

NOTE:

• Side retainer shim of each side should be kept

together with its mating retainer.

• Keep the side retainers separate by attaching

tags or in similar ways to make it possible to identify

RH and LH sides during reassembly.

ST 398457700 ATTACHMENT

6) Pull out the differential case assembly from the

differential carrier.

NOTE:

Be careful not to hit the teeth of hypoid driven gear

against the differential carrier.

7) Remove the oil seal and O-ring from the side re-

tainer.

8) When replacing the side bearing, remove the

bearing race from the side retainer using ST.

ST 398527700 PULLER ASSY

(A) Air breather cap

(B) Rear cover

DI-00061

(A)

(B)

DI-00672

DI-00064

DI-00065

DI-00066

15WRX_STI_US_EN.book 23 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-24

Rear Differential (T-type)

DIFFERENTIALS

9) Using the ST, remove the bearing cone.

NOTE:

• Do not attempt to disassemble the parts unless

necessary.

• Set the ST so that its claws catch the edge of the

bearing cone.

• Never mix up the RH and LH bearing races and

cones.

ST 18759AA000 PULLER ASSY

10) Remove the hypoid driven gear by loosening

hypoid driven gear bolts.

11) Remove the pinion shaft lock pin from hypoid

driven gear side using ST.

ST 899904100 STRAIGHT PIN REMOVER

12) Draw out the pinion mate shaft, and remove

pinion mate gears, pinion mate gear washers, side

gears, and side gear thrust washers.

NOTE:

The gears and washers should be marked with RH

or LH, front or rear, or kept separately.

13) Remove the self-locking nut while securing the

companion flange with ST.

ST 498427200 FLANGE WRENCH

14) Extract the companion flange with a puller.

DI-00316

DI-00068

DI-00701

(A) Side gear

(B) Pinion mate gear

(D) Differential case

(E) Pinion mate shaft

(F) Pinion mate gear washer

(A) Companion flange

(B) Puller

DI-00685

(E)

(D)

(F)

(B)

(A)

(C)

(A)

(C)

DI-00071

DI-00142

(B)

(A)

15WRX_STI_US_EN.book 24 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-25

Rear Differential (T-type)

DIFFERENTIALS

15) Press the end of drive pinion shaft using ST

and remove the rear bearing cone, preload adjust-

ing spacer and washer.

NOTE:

Hold the drive pinion so as not to drop it.

ST 398467700 DRIFT

16) Remove the rear bearing cone from drive pin-

ion by supporting the cone with ST.

NOTE:

Place the replacer so that its center-recessed side

faces the bearing cone.

ST 398517700 REPLACER

17) Remove the front oil seal from differential carri-

er using ST.

ST 398527700 PULLER ASSY

18) Remove the pilot bearing together with the front

bearing cone and spacer using the ST.

ST 398467700 DRIFT

19) When replacing the bearings, use a brass bar

to tap out the front bearing race and rear bearing

race in this order to remove them.

(A) Differential carrier

(B) Front oil seal

DI-00073

DI-00074

DI-00145

(B)

(A)

(A) Pilot bearing

(B) Spacer

(D) Rear bearing race

(A) 2 cutout portions along diagonal lines

(B) Tap alternately with brass bar.

DI-00076

(B)

(A)

(C)

(D)

DI-00077

(B)

(A)

15WRX_STI_US_EN.book 25 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-26

Rear Differential (T-type)

DIFFERENTIALS

2. T-TYPE (H5)

To detect the real cause of trouble, inspect the fol-

lowing items before disassembling.

• Tooth contact and backlash between hypoid

driven gear and drive pinion

• Hypoid driven gear runout on its back surface

• Total preload of drive pinion

1) Set the ST on vise and install the differential as-

sembly to ST.

ST 398217700 ATTACHMENT SET

2) Remove the drain plug and the oil temperature

sensor, and drain the gear oil.

NOTE:

Remove the oil temperature sensor and the adapt-

er as a unit.

3) Remove the air breather cap.

NOTE:

• Do not attempt to remove the air breather cap

unless necessary.

• Whenever the air breather cap is removed, re-

place it with a new part.

4) Remove the bolts, and then remove the rear

cover.

5) Remove the side retainer attachment bolts, set

the ST to differential case, and extract the side re-

tainers RH and LH with a puller.

NOTE:

• Side retainer shim of each side should be kept

together with its mating retainer.

• Keep the side retainers separate by attaching

tags or in similar ways to make it possible to identify

RH and LH sides during reassembly.

ST 398457700 ATTACHMENT

6) Pull out the differential case assembly from the

differential carrier.

NOTE:

Be careful not to hit the teeth of hypoid driven gear

against the differential carrier.

7) Remove the oil seal and O-ring from the side re-

tainer.

(A) Air breather cap

(B) Rear cover

(D) Drain plug

DI-00061

DI-01003

(A)

(D)

(C)

(B)

DI-00064

DI-00065

15WRX_STI_US_EN.book 26 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-27

Rear Differential (T-type)

DIFFERENTIALS

8) When replacing the side bearing, remove the

bearing race from the side retainer using ST.

ST 398527700 PULLER ASSY

9) Using the ST, remove the bearing cone.

NOTE:

• Do not attempt to disassemble the parts unless

necessary.

• Set the puller so that its claws catch the edge of

the bearing cone.

• Never mix up the RH and LH bearing races and

cones.

ST 18759AA000 PULLER ASSY

10) Remove the hypoid driven gear by loosening

hypoid driven gear bolts.

NOTE:

Do not disassemble the differential case assembly.

11) Remove the self-locking nut while securing the

companion flange with ST.

ST 18633AA000 WRENCH COMPL

12) Extract the companion flange with a puller.

13) Press the end of drive pinion shaft by using the

ST, and remove the drive pinion shaft, rear bearing

cone, preload adjusting spacer and washer.

NOTE:

Hold the drive pinion so as not to drop it.

ST 398467700 DRIFT

DI-00066

DI-00316

DI-00068

(A) Companion flange

(B) Puller

DI-00071

DI-00142

(B)

(A)

DI-00073

15WRX_STI_US_EN.book 27 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-28

Rear Differential (T-type)

DIFFERENTIALS

14) Remove the rear bearing cone from drive pin-

ion by supporting the cone with ST.

NOTE:

Place the replacer so that its center-recessed side

faces the bearing cone.

ST 398517700 REPLACER

15) Remove the front oil seal from differential carri-

er using ST.

ST 398527700 PULLER ASSY

16) Remove the pilot bearing together with the front

bearing cone and spacer using the ST.

ST 398467700 DRIFT

17) When replacing the bearings, use a brass bar

to tap out the front bearing race and rear bearing

race in this order to remove them.

(A) Differential carrier

(B) Front oil seal

DI-00074

DI-00145

(B)

(A)

(A) Pilot bearing

(B) Spacer

(D) Rear bearing race

(A) 2 cutout portions along diagonal lines

(B) Tap alternately with brass bar.

DI-00076

(B)

(A)

(C)

(D)

DI-00077

(B)

(A)

15WRX_STI_US_EN.book 28 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-29

Rear Differential (T-type)

DIFFERENTIALS

D: ASSEMBLY

1. T-TYPE (B1, B2)

NOTE:

• Assemble in the reverse order of disassembly.

• Check and adjust each part during assembly.

• Keep the shims and washers in order, so that

they are not improperly installed.

• Thoroughly clean the surfaces on which the

shims, washers and bearings are to be installed.

• Apply gear oil when installing the bearings and

thrust washers.

• Be careful not to mix up the RH and LH bearing

races.

• Use a new O-ring and gasket.

• Replace the oil seal with a new part at every dis-

assembly.

• Be careful not to mix up the rear differential side

oil seal RH and LH.

• Apply differential gear oil to the lips when install-

ing the oil seal.

1) Adjusting preload for front and rear bearings

NOTE:

Adjust the bearing preload between front and rear

bearings with preload adjusting spacer and wash-

er. Pinion height adjusting washer is not affected by

this adjustment. The adjustment must not be car-

ried out with oil seal inserted.

(1) Install the rear bearing race into the differen-

tial carrier using ST1 and ST2.

ST1 398477701 HANDLE

ST2 398477703 DRIFT 2

(2) Install the front bearing race to the differen-

tial carrier using ST1 and ST2.

NOTE:

Use a new front bearing race.

ST1 398477701 HANDLE

ST2 398477702 DRIFT

(3) Insert ST1 into the differential carrier with

the pinion height adjusting washer and rear

bearing cone fitted onto it.

NOTE:

• At this time, install a provisionally selected or

previously used pinion height adjusting washer.

Measure and record the thickness.

• If tooth contact (drive pinion, hypoid driven gear)

is normal in the inspection before disassembling,

verify that the washer is not deformed, and then re-

use the used washer.

(4) Install the preload adjusting spacer and

washer, front bearing cone, ST2, companion

flange and self-locking nut.

NOTE:

Use new front bearing cone.

ST1 398507702 DUMMY SHAFT

ST2 398507703 DUMMY COLLAR

DI-00697

DI-00079

ST2

ST1

(A) Pinion height adjusting washer

(B) Preload adjusting spacer

DI-00080

(B)

(A)

(C)

ST2

ST1

15WRX_STI_US_EN.book 29 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-30

Rear Differential (T-type)

DIFFERENTIALS

(5) Turn the ST1 by hand to smooth the bear-

ing, and tighten the self-locking nut while mea-

suring the initial load or initial torque with a

spring scale or torque wrench. Select the pre-

load adjusting washer and spacer so that the

specified preload is obtained when nut is tight-

ened to the specified torque.

NOTE:

• Measure the preload in direction of tangent to the

flange.

• Be careful not to give excessive preload.

• When tightening the self-locking nut, lock ST1

with ST2 as shown in the figure.

ST1 398507702 DUMMY SHAFT

ST2 398507704 BLOCK

Tightening torque:

181.5 N·m (18.5 kgf-m, 133.9 ft-lb)

Initial load:

18.1 — 38.8 N (1.8 — 4.0 kgf, 4.1 — 8.7 lbf)

Initial torque:

0.69 — 1.47 N·m (0.07 — 0.15 kgf-m, 0.51 —

1.08 ft-lb)

DI-00081

ST1

ST2

DI-00117

Preload adjusting washer

Part No. Thickness mm (in)

383705200 2.59 (0.1020)

383715200 2.57 (0.1012)

383725200 2.55 (0.1004)

383735200 2.53 (0.0996)

383745200 2.51 (0.0988)

383755200 2.49 (0.0980)

383765200 2.47 (0.0972)

383775200 2.45 (0.0965)

383785200 2.43 (0.0957)

383795200 2.41 (0.0949)

383805200 2.39 (0.0941)

383815200 2.37 (0.0933)

383825200 2.35 (0.0925)

383835200 2.33 (0.0917)

383845200 2.31 (0.0909)

Preload adjusting spacer

Part No. Length mm (in)

383695201 56.2 (2.213)

383695202 56.4 (2.220)

383695203 56.6 (2.228)

383695204 56.8 (2.236)

383695205 57.0 (2.244)

383695206 57.2 (2.252)

DI-00481

15WRX_STI_US_EN.book 30 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-31

Rear Differential (T-type)

DIFFERENTIALS

2) Adjusting drive pinion height:

Adjust the drive pinion height with pinion height ad-

justing washer installed between the rear bearing

cone and the back of pinion gear.

(1) Attach the ST2.

ST1 398507702 DUMMY SHAFT

ST2 398507701 DIFFERENTIAL CARRIER

GAUGE

ST3 398507703 DUMMY COLLAR

(2) Measure the clearance “N” between the end

of ST2 and the end surface of ST1 by using a

thickness gauge.

NOTE:

Make sure there is no clearance between the differ-

ential carrier and ST2.

ST1 398507702 DUMMY SHAFT

ST2 398507701 DIFFERENTIAL CARRIER

GAUGE

(3) Obtain the thickness of pinion height adjust-

ing washer to be inserted from the following for-

mula, and replace the temporarily installed

washer with this one.

T = To + N – (H × 0.01) – 0.20 mm (0.0079 in)

(Example of calculation)

To = 3.39 mm (0.1335 in)

N = 0.24 mm (0.0094 in)

H = + 1

T = 3.39 mm (0.1335 in) + 0.24 mm (0.0094 in)

– 0.01 mm (0.0004 in) – 0.20 mm (0.0079 in) =

3.42 mm (0.1346 in)

Result: Thickness = 3.42 mm (0.1346 in)

Therefore use washer 383605200.

(A) Pinion height adjusting washer

DI-00083

(A)

ST2ST3 ST1

DI-00084

ST2

ST1

Thickness of pinion height adjusting

washer mm (in)

Thickness of washer temporarily

inserted mm (in)

N Clearance of thickness gauge mm (in)

H Figure marked on drive pinion head

Memo:

Pinion height adjusting washer

Part No. Thickness mm (in)

383495200 3.09 (0.1217)

383505200 3.12 (0.1228)

383515200 3.15 (0.1240)

383525200 3.18 (0.1252)

383535200 3.21 (0.1264)

383545200 3.24 (0.1276)

383555200 3.27 (0.1287)

383565200 3.30 (0.1299)

383575200 3.33 (0.1311)

383585200 3.36 (0.1323)

383595200 3.39 (0.1335)

383605200 3.42 (0.1346)

383615200 3.45 (0.1358)

383625200 3.48 (0.1370)

383635200 3.51 (0.1382)

383645200 3.54 (0.1394)

383655200 3.57 (0.1406)

383665200 3.60 (0.1417)

383675200 3.63 (0.1429)

383685200 3.66 (0.1441)

15WRX_STI_US_EN.book 31 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-32

Rear Differential (T-type)

DIFFERENTIALS

3) Install the selected pinion height adjusting wash-

er on drive pinion, and press the rear bearing cone

into position with ST.

ST 398177700 INSTALLER

4) Insert the drive pinion into the differential carrier,

and install the preselected preload adjusting spac-

er and washer.

5) Press-fit the front bearing cone with ST1, ST2

and ST3.

ST1 398507703 DUMMY COLLAR

ST2 399780104 WEIGHT

ST3 899580100 INSTALLER

6) Insert the spacer, then press-fit the pilot bearing

with ST1 and ST2.

NOTE:

Use a new pilot bearing.

ST1 399780104 WEIGHT

ST2 899580100 INSTALLER

7) Using the ST, install the oil seal.

NOTE:

• Use a new oil seal.

• Press-fit until the oil seal end comes 1 mm (0.04

in) inward from end of carrier.

• Apply differential gear oil to the oil seal lips.

ST 498447120 INSTALLER

8) Press-fit the companion flange with ST1 and

ST2.

NOTE:

Be careful not to damage the bearing.

ST1 899874100 INSTALLER

ST2 399780104 WEIGHT

(A) Drive pinion

(B) Preload adjusting spacer

(D) Differential carrier

DI-00085

DI-00704

(A)

(B)

(C)

(D)

DI-00087

ST3

ST1

ST2

DI-00088

ST2

ST1

DI-00089

DI-00090

ST1

ST2

15WRX_STI_US_EN.book 32 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-33

Rear Differential (T-type)

DIFFERENTIALS

9) Apply seal material on the drive pinion shaft

thread and new self-locking nut seat.

Seal material:

THREE BOND 1324 (Part No. 004403042) or

equivalent

10) Attach the new self-locking nut and use the ST

to fix the companion flange in place, then tighten

the self-locking nut.

Tightening torque:

181.5 N·m (18.5 kgf-m, 133.9 ft-lb)

ST 498427200 FLANGE WRENCH

11) Check the initial torque or initial load.

Initial load:

18.1 — 38.8 N (1.8 — 4.0 kgf, 4.1 — 8.7 lbf)

Initial torque:

0.69 — 1.47 N·m (0.07 — 0.15 kgf-m, 0.51 —

1.08 ft-lb)

12) Assembling differential case

(1) Install the side gears and pinion mate gears,

with their side gear thrust washers, pinion mate

gear washer, and pinion mate shaft, into the dif-

ferential case.

NOTE:

• Apply gear oil on both sides of the washer and on

the pinion mate shaft before installing.

• Insert the pinion mate shaft into the differential

case by aligning the pin holes.

(2) Measure the side gear backlash.

Side gear backlash:

0.10 — 0.20 mm (0.004 — 0.008 in)

(3) Adjust the backlash as specified by select-

ing side gear thrust washer.

DI-00091

DI-00117

DI-00481

Side gear thrust washer

Part No. Thickness mm (in)

383445201 0.75 — 0.80 (0.0295 — 0.0315)

383445202 0.80 — 0.85 (0.0315 — 0.0335)

383445203 0.85 — 0.90 (0.0335 — 0.0354)

DI-00686

DI-00240

15WRX_STI_US_EN.book 33 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-34

Rear Differential (T-type)

DIFFERENTIALS

(4) Check the condition of rotation after apply-

ing oil to the gear tooth surfaces and washer

surfaces.

(5) Drive the pinion shaft lock pin into the differ-

ential case.

NOTE:

Use a new pinion shaft lock pin.

ST 899904100 STRAIGHT PIN REMOVER

13) Install the driven gear to the differential case.

NOTE:

• Before installing bolts, apply seal material to bolt

threads.

Seal material:

THREE BOND 1324 (Part No. 004403042) or

equivalent

• Make sure there is no clearance between the dif-

ferential case and driven gear.

• Tighten opposing bolts in order.

Tightening torque:

103 N·m (10.5 kgf-m, 76.0 ft-lb)

14) Using the ST, press-fit the side bearing to the

differential case.

ST 398487700 DRIFT

15) Using the ST, press-fit the side bearing outer

race to the side retainer.

CAUTION:

Make sure that the bearing outer races and

cones are properly assembled.

ST 398417700 DRIFT

16) Side retainer shim adjustment

(1) The hypoid driven gear backlash and side

bearing preload can be adjusted by the side re-

tainer shim thickness.

(2) Install the differential case assembly into dif-

ferential carrier in the reverse order of disas-

sembly.

NOTE:

Be careful not to hit the teeth of hypoid driven gear

against the differential carrier.

(3) Install the side retainer shim.

NOTE:

• Be careful not to mix up the side retainer shim

RH and LH.

• Replace broken or corroded side retainer shims

with a new part of the same thickness.

DI-00068

DI-00095

Side retainer shim

Part No. Thickness mm (in)

383475201 0.20 (0.0079)

383475202 0.25 (0.0098)

383475203 0.30 (0.0118)

383475204 0.40 (0.0157)

383475205 0.50 (0.0197)

DI-00324

DI-00065

15WRX_STI_US_EN.book 34 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-35

Rear Differential (T-type)

DIFFERENTIALS

(4) Align the arrow mark on the differential car-

rier with the arrow mark on the side retainer

when installing the side retainer.

NOTE:

Be careful that the side bearing outer race is not

damaged by the bearing roller.

(5) Tighten the side retainer bolts.

Tightening torque:

10.5 N·m (1.1 kgf-m, 7.7 ft-lb)

(6) Measure the hypoid driven gear to drive pin-

ion backlash. Set the magnet base on differen-

tial carrier. Align the contact point of dial gauge

with tooth face of hypoid driven gear, and move

hypoid driven gear while holding drive pinion

still. Read the value indicated on dial gauge. If

the backlash is outside the standard range, ad-

just the side retainer shim by the following

method.

• When backlash is less than 0.1 mm (0.004

in):

Reduce the thickness of shim on the back side

of the hypoid driven gear and increase the

thickness of shims on the teeth side of the hy-

poid driven gear.

• When backlash exceeds 0.2 mm (0.008 in):

Increase the thickness of shim on the back side

of the hypoid driven gear and reduce the thick-

ness of shims on the teeth side of the hypoid

driven gear.

Backlash:

0.10 — 0.20 mm (0.004 — 0.008 in)

(7) Measure the total preload of the drive pin-

ion. If the total preload is outside the specifica-

tion range, adjust the thickness of side retainer

shims, increasing/reducing both shims by an

even amount at a time.

Total preload:

20.7 — 54.4 N (2.1 — 5.5 kgf, 4.7 — 12.2 lbf)

(A) Arrow mark (on the side retainer)

(B) Arrow mark (on the differential carrier)

DI-00543

(B)

(A)

DI-00487

DI-00099

15WRX_STI_US_EN.book 35 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-36

Rear Differential (T-type)

DIFFERENTIALS

17) Recheck the hypoid driven gear to drive pinion

backlash.

Backlash:

0.10 — 0.20 mm (0.004 — 0.008 in)

18) Check pinion and hypoid driven gears rotate

smoothly and make sure of the hypoid driven gear

runout on its back surface. If the hypoid driven gear

runout on its back surface exceeds the specifica-

tion, check for any foreign objects between the hy-

poid driven gear and differential case, and for any

deformation of the differential case or hypoid driven

gear.

Hypoid driven gear back surface runout:

0.05 mm (0.002 in)

19) Check and adjustment of the tooth contact of

hypoid driven gear and drive pinion

(1) Apply lead-free red dye evenly on the both

sides of three to four teeth of the hypoid driven

gear. Check the contact pattern after rotating

the hypoid driven gear several revolutions back

and forth until a definite contact pattern appears

on the hypoid driven gear.

(2) When the contact pattern is not correct, re-

adjust.

NOTE:

Be sure to wipe off the lead-free red dye completely

after the adjustment is completed.

• Correct tooth contact

Check item: Tooth contact pattern is slightly

shifted toward toe side under no-load rota-

tion. (When driving, it moves towards the

heel side.)

DI-00099

DI-00101

(A) Toe side

(B) Heel side

(A)

(B)

MT-01401

15WRX_STI_US_EN.book 36 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-37

Rear Differential (T-type)

DIFFERENTIALS

• Face contact

Check item: Backlash is too large.

Contact pattern

Corrective action: Increase thickness of pinion

height adjusting washer according to the proce-

dure for bringing drive pinion close to hypoid

driven gear side.

• Flank contact

Check item: Backlash is too small.

Contact pattern

Corrective action: Reduce the thickness of pin-

ion height adjusting washer according to the

procedure for bringing drive pinion away from

hypoid driven gear.

AT-00208

AT-00212

AT-00209

AT-00213

15WRX_STI_US_EN.book 37 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-38

Rear Differential (T-type)

DIFFERENTIALS

• Toe contact (inside contact)

Check item: Teeth contact area is too small.

Contact pattern

Corrective action: Reduce the thickness of pin-

ion height adjusting washer according to the

procedure for bringing drive pinion away from

hypoid driven gear.

• Heel contact (outside end contact)

Check item: Teeth contact area is too small.

Contact pattern

Corrective action: Increase thickness of pinion

height adjusting washer according to the proce-

dure for bringing drive pinion close to hypoid

driven gear side.

AT-00210

AT-00213

AT-00211

AT-00212

15WRX_STI_US_EN.book 38 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-39

Rear Differential (T-type)

DIFFERENTIALS

20) If proper tooth contact is not obtained, readjust

the drive pinion height by changing the RH and LH

side retainer shims and the hypoid gear backlash.

(1) Drive pinion height

ST1 398507702 DUMMY SHAFT

ST2 398507701 DIFFERENTIAL CARRIER

GAUGE

T = To + N – (H × 0.01) – 0.20 mm (0.0079 in)

(2) Hypoid gear backlash

Backlash:

0.10 — 0.20 mm (0.004 — 0.008 in)

21) Remove the RH and LH side retainers.

22) Install the O-ring to left and right side retainers.

NOTE:

Use new O-rings.

23) Install the oil seal to the side retainers on both

sides. <Ref. to DI-55, REPLACEMENT, Rear Dif-

ferential Side Oil Seal.>

24) Align the arrow mark on the differential carrier

with the arrow mark on the side retainer when in-

stalling the side retainer.

25) Apply liquid gasket to the bolts indicated by ar-

rows, and tighten the bolts.

Liquid gasket:

THREE BOND 1110F, THREE BOND 1110B or

equivalent

Tightening torque:

10.5 N·m (1.1 kgf-m, 7.7 ft-lb)

26) Install the gasket and rear cover, and tighten

the bolts to specified torque.

NOTE:

Use a new gasket.

Tightening torque:

29.5 N·m (3.0 kgf-m, 21.8 ft-lb)

Thickness of pinion height adjusting

washer mm (in)

Thickness of washer temporarily

inserted mm (in)

N Clearance of thickness gauge mm (in)

H Figure marked on drive pinion head

Memo:

DI-00084

ST2

ST1

DI-00099

(A) Arrow mark (on the side retainer)

(B) Arrow mark (on the differential carrier)

DI-00543

(B)

(A)

DI-00461

DI-00490

15WRX_STI_US_EN.book 39 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-40

Rear Differential (T-type)

DIFFERENTIALS

27) Install the air breather cap.

NOTE:

When installing the air breather cap, do not tap sec-

tion (A). Be sure to tap section (B) to install.

28) Install the drain plug.

NOTE:

Apply liquid gasket to the drain plug.

Liquid gasket:

THREE BOND 1105 (Part No. 004403010) or

equivalent

Tightening torque:

49 N·m (5.0 kgf-m, 36.1 ft-lb)

29) Install the filler plug.

NOTE:

After installing the rear differential assembly to the

vehicle, fill the gear oil, then apply liquid gasket,

and tighten to the specified torque. <Ref. to DI-16,

REPLACEMENT, Differential Gear Oil.>

2. T-TYPE (H5)

NOTE:

• Assemble in the reverse order of disassembly.

• Check and adjust each part during assembly.

• Keep the shims and washers in order, so that

they are not improperly installed.

• Thoroughly clean the surfaces on which the

shims, washers and bearings are to be installed.

• Apply gear oil when installing the bearings and

thrust washers.

• Be careful not to mix up the RH and LH bearing

races.

• Use a new O-ring and gasket.

• Replace the oil seal with a new part at every dis-

assembly.

• Be careful not to mix up the oil seal RH and LH.

• Apply differential gear oil to the lips when install-

ing the oil seal.

1) Adjusting preload for front and rear bearings

NOTE:

Adjust the bearing preload between front and rear

bearings with spacer and washer. Pinion height ad-

justing washer is not affected by this adjustment.

The adjustment must not be carried out with oil seal

inserted.

2) Using the ST, press-fit the rear bearing race to

the differential carrier.

ST 398417700 DRIFT

DI-00674

(A)

(B)

DI-00697

DI-00318

15WRX_STI_US_EN.book 40 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-41

Rear Differential (T-type)

DIFFERENTIALS

3) Using the ST, press-fit the front bearing race to

the differential carrier.

NOTE:

Use a new front bearing race.

ST 398477702 DRIFT

4) Selecting the pinion height adjusting washer

(1) Measure the thickness of the inserted pinion

height adjusting washer.

(2) Read the markings on both the current drive

pinion gear and the new pinion gear.

NOTE:

No marking means 0 (zero).

(3) Calculate the thickness of pinion height ad-

justing washer to be inserted from the following

formula, and replace the installed washer with a

new washer of the calculated thickness.

T = T1 + (T2 × 0.01 – T3 × 0.01)

(Example of calculation)

T1 = 3.30 mm (0.1299 in), T2 = +2, T3 = –1

T = 3.30 mm (0.1299 in) + {(2 × 0.01) – (–1 ×

0.01)} = 3.33 mm (0.1311 in)

Result: Thickness = 3.33 mm (0.1311 in)

The washer with part number 38336AA310 is

used.

DI-00319

DI-00320

DI-00321

Thickness of selected pinion height adjusting

washer mm (in)

Thickness of inserted pinion height adjusting

washer mm (in)

Number of the installed drive pinion gear mark-

ing mm (in)

Number of new drive pinion gear marking mm

(in)

Memo:

Pinion height adjusting washer

Part No. Thickness mm (in)

38336AA230 3.09 (0.1217)

38336AA240 3.12 (0.1228)

38336AA250 3.15 (0.1240)

38336AA260 3.18 (0.1252)

38336AA270 3.21 (0.1264)

38336AA280 3.24 (0.1276)

38336AA290 3.27 (0.1287)

38336AA300 3.30 (0.1299)

38336AA310 3.33 (0.1311)

38336AA320 3.36 (0.1323)

38336AA330 3.39 (0.1335)

38336AA340 3.42 (0.1346)

38336AA350 3.45 (0.1358)

38336AA360 3.48 (0.1370)

38336AA370 3.51 (0.1382)

38336AA380 3.54 (0.1394)

38336AA390 3.57 (0.1406)

38336AA400 3.60 (0.1417)

38336AA410 3.63 (0.1429)

38336AA420 3.66 (0.1441)

15WRX_STI_US_EN.book 41 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-42

Rear Differential (T-type)

DIFFERENTIALS

5) Install the selected pinion height adjusting wash-

er on drive pinion, and push the rear bearing cone

into position with ST.

ST 18674AA000 INSTALLER

6) Insert the drive pinion into the differential carrier,

and install the originally attached preload adjusting

spacer and washer.

7) Install the front bearing cone.

NOTE:

Use new front bearing cone.

8) Insert the spacer and press-fit the pilot bearing

using ST.

NOTE:

Use a new pilot bearing.

ST1 399780104 WEIGHT

ST2 899580100 INSTALLER

ST3 398507703 DUMMY COLLAR

ST4 498937110 HOLDER DRIVE PINION

9) Press-fit the companion flange with ST1, ST2,

and ST3.

NOTE:

Be careful not to damage the bearing.

ST1 899874100 INSTALLER

ST2 399780104 WEIGHT

ST3 498937110 HOLDER DRIVE PINION

10) Attach the self-locking nut and use the ST to fix

the companion flange in place, then tighten the

self-locking nut.

Tightening torque:

181.5 N·m (18.5 kgf-m, 133.9 ft-lb)

ST 18633AA000 WRENCH COMPL

(A) Drive pinion

(B) Preload adjusting spacer

(D) Differential carrier

DI-00085

DI-00704

(A)

(B)

(C)

(D)

ST2

ST3

ST1

ST4

ST1

ST4

DI-00322

ST3

ST1

ST2

DI-00323

DI-00091

15WRX_STI_US_EN.book 42 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-43

Rear Differential (T-type)

DIFFERENTIALS

11) Rotate the drive pinion shaft 10 times or more

to fit it in the respective taper roller bearing, and

then measure the initial load or initial torque.

Initial load:

24.1 — 38.6 N (2.5 — 3.9 kgf, 5.4 — 8.7 lbf)

Initial torque:

0.98 — 1.57 N·m (0.10 — 0.16 kgf-m, 0.72 —

1.16 ft-lb)

12) When the bearing preload is out of the speci-

fied range, select the preload adjusting washer and

spacer from the following table in order to make it

within the specified range.

13) Remove the self-locking nut while securing the

companion flange with ST.

ST 18633AA000 WRENCH COMPL

DI-00715

DI-00481

Preload adjusting washer

Part No. Thickness mm (in)

383705200 2.59 (0.1020)

383715200 2.57 (0.1012)

383725200 2.55 (0.1004)

383735200 2.53 (0.0996)

383745200 2.51 (0.0988)

383755200 2.49 (0.0980)

383765200 2.47 (0.0972)

383775200 2.45 (0.0965)

383785200 2.43 (0.0957)

383795200 2.41 (0.0949)

383805200 2.39 (0.0941)

383815200 2.37 (0.0933)

383825200 2.35 (0.0925)

383835200 2.33 (0.0917)

383845200 2.31 (0.0909)

Preload adjusting spacer

Part No. Length mm (in)

31454AA130 52.2 (2.055)

31454AA140 52.4 (2.063)

31454AA150 52.6 (2.071)

31454AA160 52.8 (2.079)

31454AA170 53.0 (2.087)

31454AA180 53.2 (2.094)

DI-00091

15WRX_STI_US_EN.book 43 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-44

Rear Differential (T-type)

DIFFERENTIALS

14) Extract the companion flange with a puller.

15) Using the ST, install the oil seal.

NOTE:

• Use a new oil seal.

• Press-fit until the oil seal end comes 1 mm (0.04

in) inward from end of carrier.

• Apply differential gear oil to the oil seal lips.

ST 498447120 INSTALLER

16) Press-fit the companion flange with ST1, ST2,

and ST3.

ST1 899874100 INSTALLER

ST2 399780104 WEIGHT

ST3 498937110 HOLDER DRIVE PINION

NOTE:

Be careful not to damage the bearing.

17) Apply seal material on the drive pinion shaft

thread and new self-locking nut seat.

Seal material:

THREE BOND 1324 (Part No. 004403042) or

equivalent

18) Attach the new self-locking nut and use the ST

to fix the companion flange in place, then tighten

the self-locking nut.

Tightening torque:

181.5 N·m (18.5 kgf-m, 133.9 ft-lb)

ST 18633AA000 WRENCH COMPL

19) Check the initial torque or initial load.

Initial load:

24.1 — 38.6 N (2.5 — 3.9 kgf, 5.4 — 8.7 lbf)

Initial torque:

0.98 — 1.57 N·m (0.10 — 0.16 kgf-m, 0.72 —

1.16 ft-lb)

(A) Companion flange

(B) Puller

DI-00142

(B)

(A)

DI-00089

ST3

ST1

ST2

DI-00323

DI-00071

DI-00715

DI-00481

15WRX_STI_US_EN.book 44 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-45

Rear Differential (T-type)

DIFFERENTIALS

20) Install the driven gear to the differential case.

NOTE:

• Before installing bolts, apply seal material to bolt

threads.

Seal material:

THREE BOND 1324 (Part No. 004403042) or

equivalent

• Make sure there is no clearance between the dif-

ferential case and driven gear.

• Tighten opposing bolts in order.

Tightening torque:

103 N·m (10.5 kgf-m, 76.0 ft-lb)

21) Using the ST, press-fit the side bearing to the

differential case.

ST 398487700 DRIFT

22) Using the ST, press-fit the side bearing outer

race to the side retainer.

CAUTION:

Make sure that the bearing outer races and

cones are properly assembled.

ST 398417700 DRIFT

23) Side retainer shim adjustment

(1) The hypoid driven gear backlash and side

bearing preload can be adjusted by the side re-

tainer shim thickness.

(2) Install the differential case assembly into dif-

ferential carrier in the reverse order of disas-

sembly.

NOTE:

Be careful not to hit the teeth of hypoid driven gear

against the differential carrier.

(3) Install the side retainer shim.

NOTE:

• Be careful not to mix up the side retainer shim

RH and LH.

• Replace broken or corroded side retainer shims

with a new part of the same thickness.

(4) During installation, align the arrow mark on

the differential carrier with the arrow mark on the

side retainer when installing the side retainer.

NOTE:

Be careful that side bearing outer race is not dam-

aged by the bearing roller.

DI-00068

DI-00095

DI-00324

Side retainer shim

Part No. Thickness mm (in)

383475201 0.20 (0.0079)

383475202 0.25 (0.0098)

383475203 0.30 (0.0118)

383475204 0.40 (0.0157)

383475205 0.50 (0.0197)

(A) Arrow mark (on the side retainer)

(B) Arrow mark (on the differential carrier)

DI-00065

DI-00543

(B)

(A)

15WRX_STI_US_EN.book 45 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-46

Rear Differential (T-type)

DIFFERENTIALS

(5) Tighten the side retainer bolts.

Tightening torque:

10.5 N·m (1.1 kgf-m, 7.7 ft-lb)

(6) Measure the hypoid driven gear to drive pin-

ion backlash. Set the magnet base on differen-

tial carrier. Align the contact point of dial gauge

with tooth face of hypoid driven gear, and move

hypoid driven gear while holding drive pinion

still. Read the value indicated on dial gauge. If

the backlash is outside the standard range, ad-

just the side retainer shim by the following

method.

• When backlash is less than 0.1 mm (0.004

in):

Reduce the thickness of shim on the back side

of the hypoid driven gear and increase the

thickness of shims on the teeth side of the hy-

poid driven gear.

• When backlash exceeds 0.2 mm (0.008

in):

Increase the thickness of shim on the back side

of the hypoid driven gear and reduce the thick-

ness of shims on the teeth side of the hypoid

driven gear.

Backlash:

0.10 — 0.20 mm (0.004 — 0.008 in)

(7) Measure the total preload of the drive pin-

ion. If the total preload is not within specifica-

tion, adjust the thickness of side retainer shims,

increasing/reducing both shims by an even

amount on both sides.

Total preload:

26.5 — 53 N (2.7 — 5.4 kgf, 6.0 — 11.9 lbf)

24) Recheck the hypoid driven gear to drive pinion

backlash.

Backlash:

0.10 — 0.20 mm (0.004 — 0.008 in)

25) Check drive pinion and hypoid driven gears ro-

tate smoothly and make sure of the hypoid driven

gear runout on its back surface. If the runout on the

back side of the hypoid driven gear exceeds the

specification, check for any foreign material be-

tween the hypoid driven gear and differential case,

and for any deformation of the case or gear.

Hypoid driven gear back surface runout:

0.05 mm (0.002 in)

DI-00487

DI-00099

DI-00101

15WRX_STI_US_EN.book 46 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-47

Rear Differential (T-type)

DIFFERENTIALS

26) Checking and adjusting the tooth contact of hy-

poid driven gear

(1) Apply lead-free red dye evenly on the both

sides of three to four teeth of the hypoid driven

gear. Check the contact pattern after rotating

the hypoid driven gear several revolutions back

and forth until a definite contact pattern appears

on the hypoid driven gear.

(2) When the contact pattern is not correct, re-

adjust.

NOTE:

Be sure to wipe off the lead-free red dye completely

after the adjustment is completed.

• Correct tooth contact

Check item: Tooth contact pattern is slightly

shifted toward toe side under no-load rota-

tion. (When driving, it moves towards the

heel side.)

• Face contact

Check item: Backlash is too large.

Contact pattern

Corrective action: Increase thickness of pinion

height adjusting washer according to the proce-

dure for bringing drive pinion close to hypoid

driven gear side.

(A) Toe side

(B) Heel side

(A)

(B)

MT-01401

AT-00208

AT-00212

15WRX_STI_US_EN.book 47 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-48

Rear Differential (T-type)

DIFFERENTIALS

• Flank contact

Check item: Backlash is too small.

Contact pattern

Corrective action: Reduce the thickness of pin-

ion height adjusting washer according to the

procedure for bringing drive pinion away from

hypoid driven gear.

• Toe contact (inside contact)

Check item: Teeth contact area is too small.

Contact pattern

Corrective action: Reduce the thickness of pin-

ion height adjusting washer according to the

procedure for bringing drive pinion away from

hypoid driven gear.

AT-00209

AT-00213

AT-00210

AT-00213

15WRX_STI_US_EN.book 48 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-49

Rear Differential (T-type)

DIFFERENTIALS

• Heel contact (outside end contact)

Check item: Teeth contact area is too small.

Contact pattern

Corrective action: Increase thickness of pinion

height adjusting washer according to the proce-

dure for bringing drive pinion close to hypoid

driven gear side.

27) If proper tooth contact is not obtained, readjust

the drive pinion height by changing the RH and LH

side retainer shims and the hypoid gear backlash.

28) Remove the RH and LH side retainers.

29) Install the O-ring to left and right side retainers.

NOTE:

Use new O-rings.

30) Install the oil seal to the side retainers on both

sides. <Ref. to DI-55, REPLACEMENT, Rear Dif-

ferential Side Oil Seal.>

31) Align the arrow mark on the differential carrier

with the arrow mark on the side retainer during in-

stallation.

32) Apply liquid gasket to the bolts indicated by ar-

rows, and tighten the side retainer bolt.

Liquid gasket:

THREE BOND 1110F (Part No. K0879Y0021),

THREE BOND 1110B or equivalent

Tightening torque:

10.5 N·m (1.1 kgf-m, 7.7 ft-lb)

33) Install the gasket and rear cover, and tighten

the bolts to specified torque.

NOTE:

Use a new gasket.

Tightening torque:

44 N·m (4.5 kgf-m, 32.5 ft-lb)

34) Install the air breather cap.

NOTE:

When installing the air breather cap, do not tap sec-

tion (A). Be sure to tap section (B) to install.

(A) Arrow mark (on the side retainer)

(B) Arrow mark (on the differential carrier)

AT-00211

AT-00212

DI-00543

(B)

(A)

DI-00461

DI-01004

(A)

(B)

15WRX_STI_US_EN.book 49 ページ２０１５年２月１３日　金曜日　午前１１時２０分

DI-50

Rear Differential (T-type)

DIFFERENTIALS

35) Install the drain plug.

NOTE:

Use a new gasket.

Tightening torque:

60 N·m (6.1 kg-m, 44.3 ft-lb)

36) Install the oil temperature sensor.

NOTE:

• Install the oil temperature sensor and the adapt-

er as a unit.

• After installing the rear differential assembly to

the vehicle, fill the gear oil, then use a new gasket,

and tighten to the specified torque. <Ref. to DI-16,

REPLACEMENT, Differential Gear Oil.>

E: INSPECTION

Wash all the disassembled parts clean, and exam-

ine them for wear, damage and other defects. Re-

pair or replace the defective parts as necessary.

1) Hypoid driven gear and drive pinion

• If there is evidently an abnormal tooth contact,

find out the cause and adjust until the teeth contact

correctly. Replace the gear if there is an excessive

worn or an incapable adjustment.

• If crack, cutout or seizure is found, replace the

parts as a set. Slight damage of some teeth can be

corrected by oil stone or the like.

2) Side gear and pinion mate gear (T-type (B1, B2))

• Replace if cracks, scoring or other defects are

evident on the tooth surface.

• Replace if thrust washer contact surface is worn

or scored. Slight damages of the surface can be

corrected by oil stones or equivalent.

3) Bearing

Replace if seizure, peeling, wear, rust, dragging

during rotation, noise or other defect is evident.

4) Thrust washer of side gear and pinion mate gear

(T-type (B1, B2))

Replace if seized, flawed, abnormally worn or hav-

ing other defects.

5) Oil seal

Replace if deformed or damaged, and at every dis-

assembling.

6) Differential carrier

Replace if the bearing bores are worn or damaged.

7) Differential case

Replace if sliding surfaces are abnormally worn,

burned, or cracked.

8) Companion flange

Replace if the oil seal lip contact surface shows

cracking.

9) Rear differential oil temperature sensor (T-type

(H5))

(1) Check that the rear differential oil tempera-

ture sensor has no deformation, cracks or other

damages.

(2) Immerse the rear differential oil temperature

sensor and a thermometer in water.

CAUTION:

Take care not to allow water to get into the rear

differential oil temperature sensor connector. If

water gets into the connector, completely re-

move any water inside.

(A) Thermometer

(B) Rear differential oil temperature sensor

DI-01005

(A)

(B)

(C)

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DI-51

Rear Differential (T-type)

DIFFERENTIALS

(3) Raise water temperature gradually, mea-

sure the resistance between the rear differential

oil temperature sensor terminals when the tem-

perature is 20°C (68°F) and 80°C (176°F).

NOTE:

• Stir the water to make the temperature of the wa-

ter as uniform as possible.

• Take the resistance value only after it becomes

steady.

• After inspection, wipe off the water completely.

1. SIDE GEAR BACKLASH (T-TYPE (B1,

B2))

Using a dial gauge, check the backlash of side

gear.

Side gear backlash:

0.10 — 0.20 mm (0.004 — 0.008 in)

If the side gear backlash is not within the specifica-

tion, select the side gear thrust washer and adjust

the side gear backlash as specified.

2. HYPOID DRIVEN GEAR BACKLASH

Using a dial gauge, check the backlash of hypoid

driven gear.

Hypoid driven gear backlash:

0.10 — 0.20 mm (0.004 — 0.008 in)

If the hypoid driven gear backlash is outside the

specification range, adjust the side bearing preload

and repair if necessary.

3. HYPOID DRIVEN GEAR RUNOUT ON ITS

BACK SURFACE

Using a dial gauge, check the hypoid driven gear

back surface runout.

Hypoid driven gear back surface runout:

0.05 mm (0.002 in)

If the hypoid driven gear runout on its back surface

exceeds the limit, replace the hypoid driven gear.

4. TOOTH CONTACT BETWEEN HYPOID

DRIVEN GEAR AND DRIVE PINION

Inspect the tooth contact between the hypoid driv-

en gear and drive pinion. <Ref. to DI-29, ASSEM-

BLY, Rear Differential (T-type).>

Water temperature Terminal No. Standard

20°C (68°F)

1 and 2

2.233 — 2.701 [kΩ]

80°C (176°F) 0.3122 — 0.3385 [kΩ]

DI-00980

DI-00315

DI-00099

DI-00101

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DI-52

Rear Differential (T-type)

DIFFERENTIALS

5. TOTAL PRELOAD

Using a spring scale, check the total preload.

Total preload:

T-type (B1, B2):

20.7 — 54.4 N (2.1 — 5.5 kgf, 4.7 — 12.2 lbf)

T-type (H5):

26.5 — 53 N (2.7 — 5.4 kgf, 6.0 — 11.9 lbf)

If the total preload is not within the specification,

adjust the side retainer shim.

6. COMPANION FLANGE

1) If rust or dirt is attached to the companion flange,

remove them.

2) Set a dial gauge at a companion flange surface

(mating surface of propeller shaft and companion

flange), and then measure the companion flange

runout.

Limit of runout:

0.08 mm (0.003 in)

3) Set the gauge inside of the companion flange,

and measure the runout.

Limit of runout:

0.08 mm (0.003 in)

4) If either runout exceeds the limit, move the

phase of companion flange and drive pinion 90°

each, and find the point where the runout is within

the limit.

5) If the runout exceeds the limit after changing the

phase, replace the companion flange and recheck

the runout.

6) If the runout exceeds the limit after replacing the

companion flange, the drive pinion may be assem-

bled incorrectly or bearing is faulty.

F: ADJUSTMENT

1. SIDE GEAR BACKLASH (T-TYPE (B1,

B2))

Adjust the side gear backlash. <Ref. to DI-29, AS-

SEMBLY, Rear Differential (T-type).>

2. HYPOID DRIVEN GEAR BACKLASH

Adjust hypoid driven gear backlash. <Ref. to DI-29,

ASSEMBLY, Rear Differential (T-type).>

3. TOOTH CONTACT BETWEEN HYPOID

DRIVEN GEAR AND DRIVE PINION

Adjust the tooth contact between hypoid driven

gear and drive pinion gear. <Ref. to DI-29, ASSEM-

BLY, Rear Differential (T-type).>

4. TOTAL PRELOAD

Adjust the side retainer shim. <Ref. to DI-29, AS-

SEMBLY, Rear Differential (T-type).>

DI-00117

DI-00360

DI-00361

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